[0001] The present invention relates to a method for consolidating foundation soils, which
is also used for lifting civil building structures and artefacts of any kind (hereinafter
globally indicated as buildings) by using expanding substances, in particular resins.
[0002] Heretofore, consolidation techniques with expanding resins have been based on a technology
that used some fixed parameters as operating procedures, and in which the expanding
resin was studied more in view of the need to raise the structure rapidly, than of
a real and definitive consolidation of the soils.
[0003] Such resins constituted by mixtures of polyols and MDI isocyanates were initially
used to raise collapsed floors, for example as described in US Patent 4,567,708.
[0004] Subsequently, such resins were progressively used also for injections under the foundations
of buildings, at different depths (see for instance the Italian patent application
no. MI96A002520 and the corresponding European patents EP 851 064 e EP 941 388).
[0005] Said patent in particular discloses the use of expanding resins with the ability
to expand in free air at least five times their initial volume, combined with a monitoring
of the raising of the structure to be consolidated. According to the teaching of said
patent, consolidation should be deemed to be achieved when the structure starts to
rise.
[0006] The building is monitored by generally using a laser level and a millimetric sensor
applied to the building structure to be consolidated.
[0007] Hence, to date the state of the art provides two teachings.
[0008] On one hand, the injection, both just below the foundation plane, and in depth, of
the expanding resin by any method (i.e. both injecting into multiple, vertically distanced
points and into an entire vertical hole obtained in the soil, as taught for example
by the patent EP 851 064), but with the provision that the level of the overlying
building must be constantly monitored, taking for granted that in the moment when
the building starts to rise a consolidation level exceeding the minimum one required
for this intervention has been obtained. It was deemed that when the dynamic thrust
of the resin inside the soil discharged its power only upwards, and thus won over
the force induced by the static load of the building, that was the moment when the
underlying soil could be considered, with reasonable certainty, consolidated.
[0009] On the other hand, the state of the art teaches the use of an expanding resin that
is capable of increasing its own volume by at least five times when expanding in free
air (free air expansion means the expansion of the material freely without said material
being confined in a predetermined volume).
[0010] Little innovation was provided, relative to what is described above, by the patent
EP 1 314 824, which simply discloses the use, to consolidate soils requiring consolidation
pressures exceeding 500 kPa, of expanding resins capable of developing pressures greater
than 500 kPa.
[0011] However, these known technologies have some drawbacks.
[0012] A first drawback is caused by the fact that the moment of consolidation is identified
as the moment when the soil and/or the overlying building start to rise.
[0013] In the course of its direct and multi-year experience, the Applicant has noted that
this system of determining the consolidation of the soil has a high likelihood of
error because it does not take into account the geo-technical characteristics of the
soil itself. Attempts have been made to overcome this drawback by conducting geo-technical
surveys, in particular performing penetration measuring tests.
[0014] Such tests are normally conducted by sampling in two or three points, adjacent to
the building to be consolidated. Considering that the composition of the soils can
vary very rapidly even at short distances, it would be necessary to perform the tests
in every injection point, which is a complicated operation, or even impossible in
some cases, in addition to being highly onerous.
[0015] The consequence of such difficulties is the lack of a parameter that allows to determine
with reasonable certainty the moment when the soil is consolidated and therefore,
though injecting the expanding resin underneath a building structure sooner or later
always leads to its rise, only in some cases does that rise correspond to the definitive
consolidation of the foundation soil, meaning by definitive consolidation of the soil
such a state of compaction as to assure stable support to the overlying structure
over time.
[0016] With the experience of thousands of interventions already made, the Applicant has
observed that in some cases the structure rises immediately with a few kilograms of
expanding material injected into the significant pressure bulb (for the definition
of significant pressure bulb, see farther on), whilst in other cases, in spite of
the repeated injection of many kilograms of expanding material, the soil fails to
rise or rises only slightly and it subsequently drops again after a short time.
[0017] For example, if a soil collapse was not caused by a collapse of the surface layers
of the soil, which are well consolidated, but by a collapse of the deeper layers,
the injection of an expanding substance into the surface layers causes an immediate
rise of the overlying structure. If the only check that consolidation has been accomplished
is based, as taught by the patents EP 851 064, EP 941 388 and EP 1 314 824, on the
rise of the soil, it is immediately apparent that in fact a mistake is made, since
in actuality there is only a false consolidation. The deep layers have not been consolidated,
in within a short time span they will cause the soil to collapse again.
[0018] The diversity of the results obtained in similar interventions, conducted in different
sites, depends on many concurrent factors, i.e. on the type of soil, on the presence
or absence of cavities, on the amplitude of the foundation plane, on the depth of
the injections, and on the quantity of water contained in the soil.
[0019] Considering that, even in the presence of geological tests, the type of soil and
its dynamic resistance can determined with precision only in part, and that such data
are in any case impossible to obtain or it is not economically feasible to verify
them in every point where the injections are to be made, merely monitoring the rise
of the structure is insufficient to determine with reasonable certainty whether consolidation
has been achieved. It is therefore indispensable to determine the state of consolidation
of the soil in a different, more reliable manner than is provided by currently known
methods.
[0020] A second drawback of currently known techniques is linked to the type of resin used.
[0021] According to the operating procedures used today, although the aforementioned patents
provide for the use of resins with free air expansion coefficient of at least five
times the initial volume, in practice the expansion coefficients of actually utilised
resins usually are 15-25 times the initial volume (operators in the industry are convinced
that the greater the expanding capacity, and the smaller the speed of expansion, the
better are the results achievable in terms of consolidation), whereto corresponds
a free air density (i.e. a density after the resin has expanded in free air) of 40-66
kg/m
3, and a compression resistance ranging from 4 to 5 kg per square centimetre.
[0022] However, it has been verified in the field that such resistance is merely theoretical,
since these resins, expanded nearly in free air, have an elastic behaviour if subjected
to compression.
[0023] In the frequent case in which a resin with the characteristics described above is
injected below the foundations and into the foundation soil, and encounters voids
due to wash-off, vertical fissures due to drying, or cavities of any kind and nature,
it momentarily expands until it fills the existing void as if it were in free air,
thus assuming the compression resistance characteristics described above.
[0024] In cases of this kind, it has been verified that the consolidation provided by the
resin is absolutely insufficient both to assure the necessary lift to support the
structure and the durability of the consolidation intervention.
[0025] It is no accident that the result of many consolidation interventions conducted with
expanding resins of the kind described above has been to provide a momentary improvement
of the static conditions of the structure but not comforted by its duration over time,
since the expanded resin, stressed by the load, tended slowly to compress, even slightly,
causing the re-opening of the cracks in the overlying structure.
[0026] In this situation, a technical task constituting the basis of the present invention
is to provide a method for consolidating foundation soils that overcomes the aforementioned
drawbacks.
[0027] In particular a technical task of the present invention is to provide a method for
consolidating foundation soils in which the achieved consolidation can be determined
with greater certainty than in currently known consolidation methods.
[0028] Another technical task of the present invention is to provide a method for consolidating
foundation soils that assures the duration of the consolidation intervention over
time.
[0029] The specified technical task and the indicated aims are substantially achieved by
a method for consolidating foundation soils as described in the appended claims.
[0030] Further features and advantages of the invention shall become more readily apparent
from the detailed description of some preferred, but not exclusive, embodiments of
a method for consolidating foundation soils, described with reference to the accompanying
drawings, in which:
- Figures 1, 2 and 3 respectively illustrate three successive operating steps of a method
according to the present invention.
[0031] The method for consolidating foundation soils of the present invention comprises
a first operating step in which a plurality of holes 1 is drilled in the soil 2 to
be consolidated, appropriately distanced from each other, with a distance between
centres, for example, of one metre. In case of consolidation of an existing building
3, the holes 1 are drilled in proximity to the foundations 4 thereof (Figure 1).
[0032] Said holes 1 can be drilled both vertical and inclined relative to the vertical,
in particular in such a way as to extend underneath the foundation plane.
[0033] Advantageously, the holes 1 involve the significant pressure bulb of the foundations
4, where the significant pressure bulb is the area of the soil underlying the foundation
plane, involved by a pressure, exerted by the foundations 4 themselves, of significant
value. Conventionally, the significant pressure bulb is identified in a band of soil
underlying the foundation plane, as wide as the base of the foundations 4 and twice
as deep (starting from the foundations) as its width.
[0034] In the second step of the method are identified, along each hole 1, one or more injection
points 5, in correspondence with which an expanding substance 6 will be injected into
the soil to compact the soil itself.
[0035] Alternatively, the injection may also involve the entire hole 1, which thus coincides
with the injection point 5.
[0036] As shown in the accompanying drawings, in the case of injection points 5 not coinciding
with the entire hole 1, for each injection point 5 is advantageously inserted into
the hole 1 a tube 7 whose lower end is in correspondence with the injection point
5, and whose upper end 9 is accessible from the exterior by an operator 10. Obviously,
the hole 1 must be drilled with sufficient diameter to allow the insertion of a number
of tubes 7 equal to the number of injection points 5.
[0037] Before starting to inject the expanding substance 6, it is necessary to determine
a minimum quantity of expanding substance 6 to be injected into each injection point
5, according both to the conditions of the soil in proximity to the injection point
5 and of the characteristics of the expanding substance 6.
[0038] It is necessary, during the injection phase, to reach or exceed said minimum quantity,
in order to assure that the soil whereon the weight of a building 3 is definitively
consolidated and stable.
[0039] In particular, according to the preferred manner of executing the present invention,
the minimum quantity of expanding substance 6 to be injected into each injection point
5 is determined according to the degree of humidity of the soil in correspondence
with the related injection point 5, in consideration of the fact that as water content
increases, soils become more prone to deformation and their resistance consequently
decreases.
[0040] Therefore, before being able to determine the minimum quantity of expanding substance
6 to be injected, a preliminary operating step is necessary during which the degree
of humidity of the soil is measured in correspondence with each injection point 5.
[0041] According to the preferred embodiment, the measurement of the degree of humidity
of the soil is obtained by measuring the electrical resistance of the soil itself,
since there is a close correlation between the water content in the soil and its electrical
resistance.
[0042] As stated, into the holes 1 are inserted the tubes 7 for the injections which are
usually made of copper or aluminium, both materials with good electrical conductivity.
[0043] In consideration then of the correlation existing between the electrical resistance
of the soil and its degree of humidity, it is sufficient to connect with an appropriate
instrument 11, to two adjacent tubes 7 driven into the soil, to be able to measure
the electrical resistance of the soil between them and thus determine the degree of
humidity of the soil in that area (Figure 2).
[0044] Advantageously in any case, in an enhanced version of the present invention, only
the end of each tube 7 are made of conducting material, in such a way as precisely
to locate the measurement in the exact injection point 5.
[0045] By conducting the measurement between each pair of (both horizontally and vertically)
adjacent injection points 5 it is possible to determine with good approximation the
electrical resistance of the soil in that area.
[0046] For example, if for a hole 1 two injection points at different depths are planned,
for each of them it will be possible to measure the electrical resistance both in
relation to the overlying or underlying injection point 5, and to the two injection
points 5 positioned at its sides in the horizontal plane (or anyway to the two injection
points 5 closest to it). By calculating the weighted average of the values thus obtained,
it will be possible to determined with good precision the electrical resistance of
that area of the soil, and consequently the degree of humidity.
[0047] Depending on requirements, the number of measurements taken may be adapted to the
individual operative case. For instance, resistance may be measured in relation to
a single injection point 5 for each hole 1.
[0048] As stated, the minimum quantity of expanding substance 6 to be injected depends on
the characteristics of the expanding substance 6, in particular on its expansion capacity.
[0049] The following Table 1 shows the free air expansion coefficients of seven types of
expanding substance 6, constituted by a resin of the type described below, generically
designated with the letters A, B, C, D, E, F, and G.
TABLE 1
|
RESIN TYPE |
|
A |
B |
C |
D |
E |
F |
G |
EXPANSION COEFFICIENT OF THE RESIN USED |
4.8 |
4.6 |
4.4 |
4.2 |
4.0 |
3.5 |
3.0 |
DENSITY AFTER EXPANSION IN FREE AIR OF THE RESIN USED, kg/m3 |
208 |
218 |
228 |
238 |
250 |
286 |
333 |
[0050] The following Table 2 instead shows the minimum quantity to be injected for each
of the resins of Table 1, as a function of the electrical resistance of the soil (and
hence of its degree of humidity).
[0051] The average data shown in this table refer to standard soils, such as clay or clay-silt
soils with the presence of sand and/or gravel, with few cavities of limited size.
Moreover, the table was determined for injection points 5 positioned at a distance
of one metre from each other.

[0052] In general, the table must be obtained empirically for each type of soil and each
type of expanding substance 6, by means of field tests. In particular, it will be
necessary to verify with appropriate tests whether for a given quantity of resin injected
for each injection point 5 a good compaction is actually achieved or not (see also
what is stated below about monitoring the soil level).
[0053] Thus, if a table similar to Table 2 is available for each type of soil, once the
resistance of the soil to be consolidated is measured in correspondence with each
injection point 5, for each of them the minimum value of expanding substance 6 to
be injected can easily be determined.
[0054] In general, the minimum quantity of expanding substance 6 to be injected into each
injection point 5 increases as the free air expansion capacity of the expanding substance
6 decreases, and as the electrical resistance of the soil
[0055] in that injection point 5 decreases.
[0056] At this point the operator 10 can start injecting the expanding substance 6 into
the soil in correspondence with each injection point 5.
[0057] During the injection, the method of the present invention also provides for the continuous
monitoring of the level of the soil and/or of a building 3 bearing thereon to determine
the rise of the soil itself, and for measuring the quantity of expanding substance
6 injected into the soil, and comparing said value with the value of the minimum quantity
to be injected, determined for that injection point 5.
[0058] As shown in Figure 3, the injection is performed by the operator 10 by means of a
gun 12 fed, through an injection pump (not shown), from a tank (not shown) of the
expanding substance 6 (or from multiple tanks, through several pumps, when the expanding
substance 6 is obtained by mixing two or more components in the injection point 5.
[0059] Both the injection pump and the conduits 13 which extend between the tank and the
gun are appropriately heated to maintain the expanding substance 6 at the optimal
temperature, in known ways.
[0060] Advantageously, the operator 10 can be provided with a display 14 enabling to view
the values of the quantity of substance 6 injected and of the rise of the soil or
of the building 3.
[0061] The injection of the expanding substance 6 is stopped when the injected quantity
is at least equal to the minimum quantity, provided the soil and/or the building 3
bearing thereon have risen by a predetermined minimum value, which is usually no less
than 1 mm.
[0062] In general, the predetermined minimum value is not a constant, but must be determined
for each intervention according to the extent of the required consolidation (this
value in particular varies with the extent of the collapses of the soil which made
the consolidation intervention necessary). Said minimum value can therefore vary also
from one point to another in the same intervention.
[0063] To assure an even better consolidation result, however, if, before reaching the minimum
quantity of expanding substance 6, the soil and/or the building 3 bearing thereon
have risen by an amount exceeding a predetermined maximum value (also variable from
one intervention to the other, similarly to the predetermined minimum value) beyond
which there is a risk of damaging the building 3, the injection step is cancelled
and a new injection point 5 for which the steps described heretofore are repeated.
Said new injection point can be selected in the same hole 1 at a different depth,
in an extension thereof, or in a new hole 1 drilled in proximity thereto.
[0064] Said procedure may be repeated several times until an injection point 5 is identified
for which a quantity of expanding substance 6 at least equal to the predetermined
minimum quantity can be injected.
[0065] The safety check described above is opportune in particular when although a soil
collapse has taken place, the surface layers of that soil are well consolidated, and
the deeper layers were the ones that collapsed (as described above in relation to
the drawbacks of currently used techniques).
[0066] In this case, all injections will have to be conducted at great depth.
[0067] According to the preferred embodiment of the method of the present invention, an
expanding substance 6 is to be used which is able to expand its own volume in free
air less than five times, and which consequently has, after free air expansion, a
density of at least 200 kg per cubic metre. Preferably, said expanding substance 6
has an expansion coefficient of between three and five times.
[0068] Advantageously, said type of expanding substance 6 used has, after expansion in free
air, a compression resistance of at least 5 kg per square centimetre, and preferably
at least 9 kg per square centimetre, with deformation of less than 0.5%.
[0069] Preferably, the expanding substance 6 is a resin which expands by means of a chemical
reaction, and which is constituted by a mixture of two components, a polyol/polyether
such as the polyol Eterol 317/X1 produced by the Company Polychem System, and an MDI
based isocyanate, such as the MDI isocyanate Desmodur VKS 20 F produced by Bayer.
[0070] According to a different embodiment of the consolidation method of the present invention,
two or more expanding substances with different expanding capacity are injected into
different injection points 5. Preferably, in any case, all expanding substances to
be used will have an expansion coefficient lower than five.
[0071] In particular, for a hole 1 where two superposed injection points 5 are planned,
in each of said two superposed injection points 5 may be injected two different expanding
substances 6, chosen in such a way that the expanding substance 6 injected into the
deeper injection point 5 has greater expansion capacity than the expanding substance
6 injected into the less deep injection point 5.
[0072] The operating steps described above can be managed directly by an operator 10, or
with the aid of a programmable electronic control unit which, for instance, can store
the data relating to the electrical resistance of the soil determining for each point
the minimum quantity of substance 6 to be injected, monitor soil level and the quantity
of substance 6 injected and disable the dispensing of the substance 6 once the aforesaid
conditions are met, or once the predetermined maximum value of rise is exceeded.
[0073] The present invention thus achieves important advantages.
[0074] In the first place, the method for consolidating foundation soils of the present
invention assures the ability to determine with greater certainty than currently known
consolidation methods the moment in which the soil can be deemed to be consolidated.
[0075] The durability of the consolidation intervention over time is thereby assured.
[0076] Additionally, considering that on average foundations are computed to discharge on
the soil from a minimum of 0.2-0.3 kg per square centimetre to a maximum of 3-3.5
kg per square centimetre, an absolute lift of at least 9 kg per square centimetre
(as is assured by the method of the present invention which uses expanding substances
able to expand less than five times), and said term means that said load bearing capacity
is guaranteed with deformations of less than 0.5%, amply complies with all safety
margins required by construction codes.
[0077] Said load bearing capacity was confirmed by conducting tests on samples of material
expanded at atmospheric pressure (in free air).
[0078] Comparative tests conducted on currently used expanding resins, with an expansion
coefficient of 15-25 times which entails theoretical compression resistance varying
from 4 to 5 kg per centimetre square, have shown that the application of a load of
4-5 kg per square centimetre to samples of such resins expanded in free air causes
deformation in proportion to the applied load, which highlight their indisputable
elastic behaviour.
[0079] Additionally, the correlation between consolidation quality to the quantity of water
present in the soil has proven, in numerous tests conducted, to be an optimal choice
which combines ease of implementation with the reliability of the information thereby
obtained.
[0080] It should further be noted that the present invention is relatively easy to implement
and that the cost connected with the implementation of the invention is not very high,
compared to industry standards.
[0081] The invention thus conceived can be subject to numerous modifications and variations,
without thereby departing from the scope of the inventive concept that characterises
it.
[0082] All components can be replaced with other, technically equivalent elements and in
practice all materials employed, as well as the shapes and sizes of the various components,
may be any depending on requirements.
1. A method for consolidating foundation soils, comprising the operative steps of:
drilling a plurality of holes (1) in the soil;
injecting into the soil through each of said holes (1) at least an expanding substance
(6) in one or more injection points (5) to compact the soil in proximity to said injection
points (5); and
monitoring the level of the soil and/or of a building (3) bearing thereon to determine
its rise;
characterised in that it further comprises, for injection in each injection point (5), the operative steps
of:
determining a minimum quantity of expanding substance (6) to be injected, both as
a function of the degree of humidity of the soil in correspondence with the related
injection point (5), and of the expansion capacity in free air of the expanding substance
(6);
measuring the quantity of expanding substance (6) injected into the soil; and
comparing the quantity of substance (6) injected to said minimum quantity;
the injection of the expanding substance (6) being stopped when the injected quantity
is at least equal to said minimum quantity, and said soil and/or the building (3)
bearing thereon have risen by a predetermined minimum value, the consolidation being
deemed to be effected in that moment.
2. A method for consolidating foundation soils as claimed in claim 1
characterised in that it further comprises, before said step of determining the minimum quantity of expanding
substance (6) to be injected, the operative step of measuring the degree of humidity
of the soil in correspondence with the injection point (5).
3. A method for consolidating foundation soils as claimed in claim 2
characterised in that said step of measuring the degree of humidity of the soil is carried out measuring
the electrical resistance of the soil itself.
4. A method for consolidating foundation soils as claimed in claim 3
characterised in that the electrical resistance of the soil is measured between pairs of adjacent injection
points (5).
5. A method for consolidating foundation soils as claimed in claim 3
characterised in that the electrical resistance of the soil is measured between pairs of adjacent holes
(1).
6. A method for consolidating foundation soils as claimed in any of the claims from 3
to 5 characterised in that the minimum quantity of expanding substance (6) to be injected into each injection
point (5) increases as the electrical resistance of the soil in that injection point (5) decreases.
7. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that the minimum quantity of expanding substance (6) to be injected into each injection
point (5) increases as the expansion capacity in free air of the expanding substance
(6) decreases.
8. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said expanding substance (6) is able to expand its volume in free air by less than
five times.
9. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said expanding substance (6) is able to expand its volume in free air by between
three and five times.
10. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said expanding substance (6) has, after expansion in free air, a density exceeding
200 kg per cubic metre.
11. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that for said injection step an expanding substance (6) is used which, after expansion
in free air, has a compression resistance of at least 5 kg per square centimetre with
deformation of less than 0.5%.
12. A method for consolidating foundation soils as claimed in claim 11
characterised in that the expanding substance (6), after expansion in free air, has a compression resistance
of at least 9 kg per square centimetre with deformation of less than 0.5%.
13. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said expanding substance (6) expands by means of a chemical reaction.
14. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said expanding substance (6) comprise a mixture of polyols/polyethers and of MDI
base isocyanate.
15. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said holes (1) are drilled vertical.
16. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said holes (1) are drilled inclined relative to the vertical.
17. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that, for each hole (1), multiple injections of expanding substance (6) are performed
in correspondence with injection points (5) located at different depths.
18. A method for consolidating foundation soils as claimed in any of the claims from 1
a 16 characterised in that, for each hole (1 ), a single injection of expanding substance (6) is performed for
the entire length of the hole (1), said hole (1) coinciding with a single injection
point (5).
19. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said minimum predetermined rise value is at least 1 mm.
20. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said injection points (5) are located below the foundations (4) of a building (3)
to be consolidated.
21. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that said injection points (5) are located inside the significant pressure bulb of the
foundations (4) of a building (3) to be consolidated.
22. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that it provides for the injection of two or more of said expanding substances (6) with
different expanding capacity, into distinct injection points (5).
23. A method for consolidating foundation soils as claimed in claim 22
characterised in that for at least a hole (1) are provided two superposed injection points (5), and in that in each of said two superposed injection points (5) are injected two different expanding
substances (6), the expanding substance (6) injected into the deeper injection point
(5) having greater expansion capacity than the expanding substance (6) injected into
the less deep injection point (5).
24. A method for consolidating foundation soils as claimed in any of the previous claims
characterised in that if the soil and/or the construction (3) which bears thereon have risen by a value
exceeding a predetermined maximum value before said minimum quantity of expanding
substance (6) has been injected, said injection step is cancelled and a new injection
point (5) is identified and for said new injection point (5) all said operative steps
are carried out.
25. A method for consolidating foundation soils as claimed in claim 24
characterised in that the identification of a new hole (1) is repeated until for an injection point (5)
the injection of the expanding substance (6) is stopped because the injected quantity
is at least equal to said minimum quantity, and said soil and/or the building (3)
which bears thereon have risen by said predetermined minimum value.